Drywall installation apparatus

ABSTRACT

A drywall installation apparatus includes a support for holding a piece of drywall to be installed on a stud wall, an extension to adjust the length of the drywall installation apparatus, and a base to which a lifting mechanism may be coupled to raise the drywall installation apparatus and the piece of drywall being supported into a desired position for installation on a stud wall. The drywall installation apparatus further includes an alignment member to assist in orienting properly the piece of sheetrock to be installed on the stud wall.

RELATED APPLICATION

[0001] Provisional Patent Application Serial No. 60/172,614, filed Dec. 20, 1999, is claimed for priority purposes. A copy of this provisional patent application is attached as Exhibit A, which is incorporated by this reference in its entirety.

TECHNICAL FIELD

[0002] This invention relates to drywall installation, and, more particularly, to drywall installation tools and methods.

BACKGROUND OF THE INVENTION

[0003] Drywall (also commonly referred to as or wallboard or sheetrock) is commonly installed on studs to form the basis for finished interior walls of residential and commercial buildings. While drywall can come in many sizes, the typical sizes for installation are in sheets four feet wide and eight or twelve feet in length. These standard pieces or sheets of drywall are heavy and difficult to install by one person alone. Accordingly, commonly at least two people work to hold and install the sheets of drywall. In construction, time is of the essence as it relates to profitability. Use of multiple people reduces efficiency and, therefore, adds to the cost of construction.

[0004] A particular problem associated with drywall or wallboard installation relates to hanging the drywall on upper portions of a stud wall. It is particularly difficult to hold drywall at elevated positions on the stud wall for installation. It is also difficult to hold the drywall so that it remains properly aligned with the stud wall, the ceiling, etc. before being secured in place.

[0005] Another problem associated with drywall installation relates to securing drywall just above the floor level. It is difficult to reach down and hold the sheetrock in place. Again, commonly two people are required to install drywall on lower areas of a stud wall.

[0006] There is a need, therefore, for a drywall installation apparatus and method that will allow a single person to hold and install drywall on a stud wall, particularly at upper reaches and lower areas of the stud wall. There is further a need to provide a drywall installation apparatus that will keep the drywall properly aligned with the studs forming the stud wall by a single person, who installs the drywall secures the drywall to the stud wall by fasteners, nails, or the like.

SUMMARY AND OBJECTS OF THE INVENTION

[0007] It is a primary object of the present invention to provide a drywall installation apparatus and method that will allow installation of a sheet of drywall on a stud wall by a single person.

[0008] Another object of the present invention is to provide a drywall installation apparatus and method that will maintain the drywall in proper alignment relative to the stud wall while the drywall is installed on the stud wall.

[0009] Another object of the invention is to provide a drywall installation apparatus that can be adjusted to accommodate various different heights for installing the drywall at different heights on a stud wall.

[0010] Yet another object of the invention is to provide a drywall installation apparatus that utilizes one of the vertical studs in a stud wall as a guide to orient the drywall being installed on the stud wall.

[0011] Another object of the present invention is to provide a drywall installation apparatus that can be utilized both to install drywall on lower areas of a stud wall just above a floor and upper reaches of the stud wall.

[0012] Yet another object of the present invention is to provide a drywall installation apparatus that supports the drywall with a cradle during installation of the drywall.

[0013] The present invention relates to a drywall installation apparatus and method, which comprises an extension, a support coupled to the extension to receive and support a piece of drywall during installation, and a base coupled to the extension. The base includes an aperture for receiving a lifting device, such as the lifting end of a roll jack. The extension is adjustable to install drywall on a stud wall at various heights. In an alternative embodiment, a kickstand may be utilized in connection with a lower support mechanism to allow a piece of drywall to be installed on a lower area of a stud wall and lifted in the desired vertical position relative to the stud wall.

[0014] Other objects, features, and advantages of the invention will become apparent from the following detailed description of the invention with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Preferred embodiments of the invention are described below with reference to the accompanying drawings:

[0016]FIG. 1 is a perspective view of a drywall installation apparatus according to the present invention;

[0017]FIG. 2 is an exploded view of the drywall installation apparatus of FIG. 1;

[0018]FIG. 3 is an enlarged partial perspective view of the drywall installation apparatus of FIG. 1;

[0019]FIG. 4 is a perspective view of an alternative embodiment of a drywall installation apparatus;

[0020]FIG. 5 is an exploded view of the alternative embodiment of the drywall installation apparatus of FIG. 4;

[0021]FIG. 6 is a perspective view showing the drywall installation apparatus of FIG. 1 in operation; and

[0022]FIG. 7 is a perspective view showing the drywall installation apparatus of FIG. 4 in operation.

DETAILED DESCRIPTION OF THE INVENTION

[0023] As shown in FIGS. 1-3, the present invention relates to a drywall installation apparatus 10 which includes generally an extension or extension section 12, a support or support section 14, and a base or base section 16. With reference to FIGS. 1 and 2, the extension section 12 more specifically comprises a tubular outer member or tubular sleeve 18 (formed preferably of square tube material), which telescopes over a lower rod 20 and an upper rod 22. Lower rod 20 includes a plurality of apertures 24, and upper rod 22 includes a plurality of apertures 26 for receiving pin assemblies 28, 30, respectively, to adjust the height of the drywall installation apparatus. Pin assembly 30 is extended through aperture 32 in the upper end oftubular sleeve 18 and through one of the apertures 26 in the upper rod 22. Pin assembly 28 is similarly inserted through aperture 34 in the tubular sleeve 18 and through one of the plurality of apertures 24 in lower rod 20. The extension 12 allows the drywall installation apparatus 10 to be adjusted over a wide range of heights. In a preferred embodiment, the drywall installation apparatus 10 can be adjusted from a minimum height of approximately two feet to a maximum height of approximately seven feet.

[0024] Upper rod 22 and lower rod 20 both have generally square cross-sections. In other words, both are tubular in configuration and generally rectangular in cross-section. Upper rod 22 has a slightly larger inside diameter as compared to the outside diameter of lower rod 20. As such, the upper rod 22 may be inserted over lower rod 20 and the two parts connected directly together, without tubular sleeve 18, to form a relatively shorter drywall installation apparatus 10. To accommodate the relatively smaller cross-sectionally dimensioned lower rod 20, an insert 25 (FIG. 2) is inserted into tubular sleeve 18 (as shown in phantom in FIG. 2) and secured in place by welding or some other suitable securement method. The insert 25 has essentially the same cross-sectional dimensions as the upper rod 22 to allow the lower rod 20 to slide inside of the tubular sleeve section 18 and held securely in place. The insert 25 includes an aperture 27 which is aligned with aperture 34 in tubular sleeve section 18 so that the pin assembly 28 can be secured through both the tubular sleeve section 18 and insert member 25.

[0025] The support section 14, as shown in FIG. 3, comprises a support plate 36, which may be in the form of a trough or cradle (as shown in the embodiment of FIGS. 1-3). Those skilled in the art will understand that the support 36 could be formed in any suitable configuration that would support the weight of a sheet of drywall and allow for installation. The support 36 is generally U-shaped, with a back wall 38, a bottom wall 40, and a front wall 42. Preferably, there is a gap 45 in front wall 42. This gap 45 is formed by edges 43 formed in front wall 42. The gap 45 allows the sheet of drywall (not shown) to rest firmly in position on the top surfaces of the studs forming a stud wall. Even when the installation apparatus 10 is raised or lowered, gap 45 allows constant, flush contact of the piece of drywall with the studs. Gussets 44 are welded between trough 36 and upper rod 22 for increased strength and stability of the drywall installation apparatus 10.

[0026] With continued reference to FIGS. 2 and 3, an alignment member 46, more specifically shown in the preferred embodiment as a stud guide 46, is secured, by welding or other suitable fastening methods, to the upper rod 22 of the drywall installation apparatus 10. The stud guide 46 comprises opposed flanges 48, 50, which are sized and spaced to be inserted over a stud forming a portion of a stud wall on which the sheet of drywall is to be installed. The opposed flanges 48, 50 are integrally connected by an integral, interconnecting wall 52, which is welded to the upper rod 22. The alignment member or stud guide 46 maintains the drywall installation apparatus in the desired position when the sheet of drywall is being raised and lowered relative to the stud wall. The stud guide 46 prevents the combined drywall and drywall installation apparatus 10 from tipping to one side or another during the installation process.

[0027] The base section 16 more specifically comprises a foot piece 54. The foot piece includes an aperture where a lifting device can be coupled so the leveraging force can be applied to lift the drywall installation apparatus in combination with the sheet of drywall for installation on a stud wall. The foot piece 54 of the base 16 comprises opposed downward extension pieces 56, 58, which extend downwardly from an integral cross member 60 which is welded, in turn, to lower rod 20. The combined downward extension sections 56, 58 and the cross member 60 form a slot or aperture 62 into which a lifting or leveraging device is inserted for lifting the combined drywall installation apparatus 10 and sheet of drywall. Those skilled in the art will understand that any configuration of a base or foot piece may be utilized so long as a lifting or leveraging force can be applied to the drywall installation apparatus 10.

[0028] An alternative embodiment of the present invention is shown in FIGS. 4-5. To install a piece of sheetrock or drywall on a lower portion of a stud wall, a specialized, alternative embodiment of the drywall installation apparatus may be used. As shown in FIG. 4, a support assembly 70 is shown, which includes a support 72 in the form of a trough or cradle, which comprises a front wall 74, a bottom wall 76, and a back wall 78. A cantilevered support arm 80 holds the trough 72 away from the lower rod 20. A stabilizing arm or gusset plate 82 interconnects the cantilevered extension arm 80 and the telescoping tubular section 84. In a preferred embodiment, the brace or gusset plate 82 is welded to the extension arm 80 and the tubular sleeve portion 84. The tubular section 84 includes an aperture 86 through which an appropriate pin assembly 87 (identical to pin assemblies 28,30 shown and described in FIGS. 1 and 2) is inserted, depending on the desired height of the trough 72.

[0029] A stand assembly 90 is installed over the lower rod 20 and secured in place through aperture 96 in tubular section 94 with an appropriate pin assembly 97 (identical to pin assemblies 28, 30 shown and described in FIGS. 1 and 2) at the lowermost aperture 24 (FIG. 3) formed in the lower rod 20. The stand assembly 90 is intended to remain in the lowermost position relative to lower rod 20 to aid in supporting the drywall installation apparatus and the sheet of drywall it holds. The stand assembly 90 includes a downwardly extending stand piece 92, which terminates at an angled edge 93 corresponding to the orientation of the floor, and a tubular, telescoping sleeve section 94, which slides over lower rod 20. It should be noted that the foot piece 54 of the base 16 in the alternative embodiment shown in FIGS. 4 and 5 is substantially identical to the foot piece and base described with respect to FIG. 3. The foot piece 54 defines an appropriately sized aperture 62 through which a lifting or leveraging device can be inserted for lifting the drywall installation apparatus 68 and the piece of drywall it is holding into an appropriate position on a stud wall.

[0030]FIG. 6 shows the operation of the drywall installation apparatus 10 shown and described with respect to FIGS. 1 and 3. Generally speaking, the embodiment of FIGS. 1-3 is utilized for installing a sheet of drywall or wallboard 100 on a stud wall 102. The stud wall will comprise a plurality of vertically aligned studs 104 secured between a top cross piece (not shown) and a bottom cross piece 106. When installing a sheet of drywall 100 to an upper portion of the stud wall 102, it can be difficult for a single person to hold the drywall in place while anchoring the piece of drywall to the stud wall. As shown in FIG. 6 the alignment member or stud guide 46 is then positioned over one of the studs 104, depending on the desired location for installing the sheet of drywall. Thereafter, an edge of the sheet of drywall 100 is placed inside the support assembly 14 of the installation apparatus 10. The overall length of the drywall installation apparatus 10 will have previously been adjusted using the telescoping extension section 12 to the appropriate size by moving the upper rod 22 and lower rod 20 relative to the tubular sleeve 18 and secured in place by pin assemblies 28 and 30. When the sheet of drywall 100 is appropriately positioned inside the support assembly 14, a conventional roll jack 110 is positioned so that the front edge of the roll jack 112 is inserted through the aperture 62 formed in the base or foot assembly 54. Thereafter, the installer's foot is placed on the rear end 114 of the roll jack and, with the weight of the installer, the roll jack 110 pivots about the fulcrum (roller 116) which places an upwardly leveraging force on the drywall installation apparatus 10 to place the sheet of drywall 100 in the appropriate position for fastening. Since the installer's foot is used to raise and hold the sheet of drywall 100 to the appropriate position for installation, and since the stud guide 46 prevents the device 10 from tipping from one side to another, the installer can easily use both hands to secure the fasteners through the sheet of drywall 100 and into the stud wall 104. The installation apparatus 10 as shown in FIG. 6 is intended to aid in installing drywall at upper reaches of a stud wall.

[0031]FIG. 7 shows the operation of the alternative embodiment of the drywall installation apparatus 68. In general, the embodiment of the drywall installation apparatus 68 shown and described with respect to FIGS. 4 and 5, and in operation shown in FIG. 7 is intended to be utilized for installing a sheet of drywall 100 on lower areas of a stud wall 102. The installation apparatus 68 is positioned to hold a piece of drywall 100 in the desired location for installation with the exception of some minor vertical positioning. The lower edge of the sheet of drywall 100 is positioned inside the support or support assembly 72 in the form of a cradle or trough. Prior to placing the piece of drywall 100 into the trough 72 of the support assembly 70, the height of the trough 72 is adjusted by moving the tubular sleeve portion 84 relative to the lower rod 20 and secured in place by inserting pin assembly 87 through the aperture 86 (FIGS. 4 and 5) of the tubular sleeve section 84 and through one of the apertures 24 formed in the lower rod 20. The stand assembly 90 assists in holding the entire installation apparatus 68 in position, including the piece of drywall 100, prior to installing the sheet of drywall 100. A conventional roll jack 110, similar to the one shown in FIG. 6, is positioned and utilized to create an upward lifting or leveraging force on the drywall installation apparatus 68 so that the operator can utilize his or her hands and secure the piece of drywall 100 in the appropriate position on stud wall 102. It will be noted that the alternative embodiment of the drywall installation apparatus 68 is utilized such that the support assembly 70 remains between the studs 104 during installation. Accordingly, no modifications are necessary to the front end of the trough (such as the gap 45 shown in the embodiment of FIGS. 1-3) to allow for flush positioning of the sheet of drywall 100 on the studs 104.

[0032] While this invention has been described with reference to certain specific embodiments and examples, it will be recognized by those skilled in the art that many variations are possible without departing from the scope and spirit of this invention. The invention, as described by the claims, is intended to cover all changes and modifications of the invention which do not depart from the spirit of the invention. The words “including” and “having,” as used in the written description and the claims, shall have the same meaning as the word “comprising.” 

1. A drywall installation apparatus, comprising: an extension section; a support coupled to the extension section, the support sized to receive and support a piece of drywall; a base coupled to the extension section opposite the support, the base being engageable by a lift mechanism to lift the drywall installation apparatus and the piece of drywall to install the piece of drywall on a stud wall.
 2. A drywall installation apparatus according to claim 1 , further comprising an alignment member coupled to the extension, the alignment member engaging a stud in the stud wall to ensure proper alignment of the piece of drywall.
 3. A drywall installation apparatus according to claim 1 , further comprising an alignment member coupled to the extension, the alignment member comprising a pair of spaced guides which straddle a stud of the stud wall to align the piece of drywall.
 4. A drywall installation apparatus according to claim 1 wherein the extension is adjustable to vary the length of the drywall installation apparatus according to a desired installation height for the piece of drywall.
 5. A drywall installation apparatus according to claim 1 wherein the extension is telescopically adjustable to vary the length of the drywall installation apparatus according to a desired installation height for the piece of drywall.
 6. A drywall installation apparatus according to claim 1 wherein the support comprises a support shelf.
 7. A drywall installation apparatus according to claim 1 wherein the support comprises a generally U-shaped cradle.
 8. A drywall installation apparatus according to claim 1 , further comprising a stand coupled to the extension, the stand supporting the drywall installation apparatus.
 9. A drywall installation apparatus according to claim 1 wherein the base comprises an aperture for receiving an end of a lifting device used to lift the combined drywall installation apparatus and piece of drywall.
 10. A drywall installation apparatus according to claim 1 wherein the base comprises an aperture for receiving an end of a roll jack used to lift the combined drywall installation apparatus and piece of drywall.
 11. A drywall installation apparatus, comprising: a support shelf to support a piece of drywall to be installed on a stud wall; a telescoping extension rod coupled to the support shelf; a base coupled to the extension rod, the base having a location for coupling a lifting device.
 12. A drywall installation apparatus according to claim 11 , further comprising an alignment member coupled to the extension rod, the alignment member engaging a stud in the stud wall to ensure proper alignment of the piece of drywall.
 13. A drywall installation apparatus according to claim 11 , further comprising an alignment member coupled to the extension rod, the alignment member comprising a pair of spaced guides which straddle a stud of the stud wall to align the piece of drywall.
 14. A drywall installation apparatus according to claim 11 wherein the extension rod is adjustable to vary the length of the drywall installation apparatus according to a desired installation height for the piece of drywall.
 15. A drywall installation apparatus according to claim 11 wherein the extension rod is telescopically adjustable to vary the length of the drywall installation apparatus according to a desired installation height for the piece of drywall.
 16. A drywall installation apparatus according to claim 11 wherein the support comprises a support shelf.
 17. A drywall installation apparatus according to claim 11 wherein the support comprises a generally U-shaped cradle.
 18. A drywall installation apparatus according to claim 11 , further comprising a stand coupled to the extension rod, the stand supporting the drywall installation apparatus.
 19. A drywall installation apparatus according to claim 11 wherein the base comprises an aperture for receiving an end of a lifting device used to lift the combined drywall installation apparatus and piece of drywall.
 20. A drywall installation apparatus according to claim 11 wherein the base comprises an aperture for receiving an end of a roll jack used to lift the combined drywall installation apparatus and piece of drywall.
 21. A method of installing a piece of sheet rock, comprising: providing an adjustable drywall installation apparatus, the drywall installation apparatus comprising an extension section, a support, and a base; placing a piece of sheet rock on the support; positioning a lifting device in an operable condition on the support; exerting a lifting force on the installation apparatus to lift the piece of drywall to a desired position for installation.
 22. The method of claim 21 , further comprising using exclusively a foot of an installer to lift the piece of drywall. 